Construction system for building housing and other shelters

ABSTRACT

A system and method for constructing housing employs a plurality of base platform sizes and then imposes restrictions on the number and sizes of rooms possible for each platform to develop a uniform building standardization wherein each subcontractor and manufacturer can achieve lower costs by standardization of materials.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates to a system and method for buildingmultiple and individual shelters utilizing base platforms of fixeddimensions to standardize building of housing and other types ofshelters with interchangeable parts and sub-assemblies.

[0003] 2. Description of the Related Art

[0004] House building is the seventh largest industry in the UnitedStates employing more than 3 million people. It is dominated by thetraditional “stick built”, one of a kind approach using variousorganizations of manufacturers and suppliers. It is organized aroundindependent trade persons and suppliers with each builder usuallybuilding fewer than 12 homes per year. Each house is literally built ona trial and error basis with the builder working with custom plans and abewildering variety of components that vary in size. A simple two footextension in house width means that the entire house or other sheltermay need to be re-calculated for cost, heating and cooling requirements,strength of beams and trusses and the like.

[0005] The standardization of lumber sizes and fasteners began in thefirst half of the 19th century. By the early 20th century standardizedplumbing, heating, cooling, electrical and other fittings became commonto the housing industry. “Kit shelters” early in the 20th Century wereoffered to reduce cost. Often referred to as “factory built”, such homescould arrive as bundles of precut lumber, in sections or in panels.“Modular homes” have been offered late in the 20th Century. They arealmost entirely factory built in trimmed out segments or boxes.Plumbing, heating, ventilation and electrical are usually completedon-site. They still require skilled tradesmen and transportation costsare very high.

[0006] The “panelized building systems” are more versatile, using openpanels, closed panels and structural insulated panels. Closed panels mayinclude wiring, insulation and a vapor barrier on the inside. Windowsand doors are usually cut in at the factory.

[0007] All of these techniques are aimed at reducing cost but sufferfrom limited economies of scale and limited selection for the consumer.

[0008] Efforts to try to reduce cost in housing include use of full sizetemplates as described in U.S. Pat. No. 4,573,302 to Caretto. Othersinvolve simple standards such as eight foot ceiling heights thatdictated sizes for sheetrock. The current popularity of nine and tenfoot ceilings has increased the expense of sheet rocking due toadditional joints that are required. A system where the manufacturersand trades work together to make custom homes without requiring customsizes is clearly desirable.

[0009] As one part of a presidential initiative, the NAHB ResearchCenter, Inc. prepared a “Report to the PATH Industry SteeringCommittee—Recommendations for PATH Technology Roadmapping” in May 2000.That Report discusses modular, whole house approaches and advancedpanelized-type systems. The Report responds to and clearly identifies anationwide need to build houses in a more affordable manner.

[0010] The art described in this section is not intended to constitutean admission that any patent, publication or other information referredto herein is “prior art” with respect to this invention, unlessspecifically designated as such. In addition, this section should not beconstrued to mean that a search has been made or that no other pertinentinformation as defined in 37 C.F.R. § 1.56(a) exists.

SUMMARY OF THE INVENTION

[0011] The invention provides a system and method for building multipleindividualized housing and other shelters at a lower cost by greatlysimplifying and limiting the number of parts and standardizing theplatforms on which they are installed. The invention relates to anoperating system for ordering, organizing and managing shelterconstruction. The system requires standardization of base platforms, ortemplates and their suitable foundation sizes and then appliesrequirements and customer selected options to determine the personalizedhouse they desire. This requires the homeowner to work within sizeconstraints selected from standardized elements that may be reproducedby the selected manufacturers and tradesmen to lower the cost ofcomponents and labor. The particular system formula desired can bedisplayed in virtual reality.

[0012] Base platform and template as used herein refer to the outsidedimensions or footprint of the home. While a person could arbitrarilypick a width of 31½ feet, such a size means that most componentsinternally would need to be cut to a non-standard size.

[0013] An example of standardization to date includes bathroom tubs,which are available in several lengths, but are not made to the owner'sspecification due to prohibitive cost. The same is true for everycomponent in a house. An off sized room means that doors, windows,plumbing connections, flooring and the like must either be adjusted inthe field by a skilled tradesman, or must be specially manufactured andstocked in many sizes. This is obviously expensive and undesirable.

[0014] The invention requires little of the home owner. They must simplyselect from a wide variety of bugetarily acceptable base platforms andthen select the number of rooms for each floor of the base platformselected. This can be accomplished in virtual reality. The number ofrooms divided into the base platform dictates room sizes to a degree,but the inventive system herein also requires that all room sizes mustbe evenly divisible by two. This imposes standardization formanufacturers and tradesmen while requiring little of the home owner.

[0015] The invention thus limits the numbers of parts that must bestocked by standardizing the entire home system, not unlike theautomobile industry's standardization of platforms and many part sizesthat make cars affordable. The system works best with all trussedsystems such that no interior walls are load bearing. This greatlysimplifies building and allows multiple conduits for mechanicals.

[0016] The system provides greater affordability at all price levels byallowing integration and management of the total home/shelter buildingprocess from design to financing. The system organizes strategicbusinesses through joint ventures/relationship enterprises that lead tothe creation of greater consumer value and satisfaction in housing. Thesystem provides an economical integration of specialized or specificskills, i.e., engineers, architects, scientists into mass marketconstruction solutions previously unavailable for any single entity. Itallows R & D product formulation, integrated construction packages, andscope and scale efficiencies to accrue to the smaller builder andmunicipal government while furthering broader and faster disseminationof technical, health and safety and environmental improvements acrossthe entire industry.

[0017] The system creates predictability, durability, dependability andaffordability through systemic integration of shared technologies in aplatform basis which creates greater efficiencies. Standardization ofprocedures and protocols allows integration of subcontractors andsuppliers as well as simplification of construction plans, documents,material lists and contracts. The simplification provides greaterefficiency through central management of processes and procedures whichallows evolution from the typical customer or one of a kind solution tomass customization. Documentation and systematization provides a recordof subsystems and locations within the house as well as exact costs andresponsibilities for more inclusive warranties and insurance packages.Construction data can be preserved and used to perfect techniquesapplicable to subsequent units.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] A detailed description of the invention is hereafter describedwith specific reference being made to the drawings in which:

[0019]FIG. 1 is a flowchart showing how platforms of the invention maybe used to dictate a particular home; and

[0020]FIG. 2 is a flowchart showing the components of a drawing package.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Studies show that the vast majority of homes under $250,000, orunder 2500 square feet exhibit a limited range of dimensions, with themost typical width being 28 feet. By limiting people to certain baseplatforms, such as 28×36, the builder and owner can accurately andquickly pick their choice of rooms, layout, sizes and build-outs whileachieving cost control. For example, the amount of siding needed wouldbe known precisely from the selected platform size and could be orderedimmediately. The windows could be chosen for that given size based on alimited number of sizes, all going into predetermined rough-openings(RO) built into the walls at a factory. The windows can then beinstalled into the RO with attachment mechanisms from the windowmanufacturer, who could design quick connects that could allow laterremoval and upgrades as the years pass. Pre-installed runs of electriccables could be made, as well as audio/video/network wiring. Knowing thebase platform in advance fixes where the heating plant would be as wellas its size and plenum runs. Truss construction allows the plenums to behidden out of sight.

[0022] The base platform can be subdivided into 4, 5 or 6 rooms. Insmaller houses, hallway use is minimized since it is inefficient use ofspace. Thus, room dimensions can be selected and limited easily. Onceset in all the designated range of templates, flooring companies couldknow the maximum dimensions and provide carpeting with less seamingneeded.

[0023] A predetermined plurality of size classes of base platforms offixed dimensions is created that serve as templates to work as astandard in dimensioning the other building components of each class ofhome. Platform sizes of small, medium, large and extra large may bedesignated, with each class size catering to a different financialsituation for the prospective home buyer. Within each class, a pluralityof platform sizes are available. Thus, the most common platform basesare currently 28×28, 28×32, 28×36, all generally square or mildlyelongated rectangles. Platforms may be stacked to any desired number offloors or arranged adjacent to each other for single story structures.

[0024] Within those common base platforms, typically the base is dividedinto 4, 5 or 6 main areas with hallways, closets and the like chosen forindividual desires of space utilization. None of these rooms will be onefoot wide and 28 feet long. Certain human need practicalities areimplicit. However, simply limiting the home buyer to avoid odd sizesimposes almost unnoticeable limits while greatly simplifying thebuilding problems. Thus, a rule that no main area dimension may beunevenly divisible by two prevents a room size of 10½ feet which is noteven noticeable to the owner. Such rules mean that all subcontractorscan deal with uniform dimensions for room sizes. Cabinet makers canstock and carry cabinets of only certain dimensions rather than havingto custom make a piece to account for an extra seven inches designed inby a builder that does not use this inventive system. Heatingcontractors can go to the job with pre-cut runs of ducting since theplans would enable stocking of standard lengths.

[0025] The invention provides a greatly reduced number of room sizesthat are available such that manufacturers can prepare materials forstock sizes, instead of making one size that must be custom worked inthe field. A standard internal wall that would be eight feet high by tenfeet long could be completely pre-built in a factory to include allservices, including studs, wiring, outlets and sheetrock that has beentaped. Installation in the field would no longer require the services ofskilled craftsmen. Instead, semiskilled laborers under the direction ofa single skilled worker could quickly assemble the components at a greatsavings in labor costs in addition to lower component cost.

[0026] The flowchart of FIG. 1 shows the steps involved in the method ofusing a platform to calibrate a home. The system employs the methodologywhich is used in connection with a computer and suitable programmingthat will keep the databases of base platform sizes, acceptable roomsizes and can calculate the room sizes that work with the base platformand display each of the resulting possible floor layouts. Block 100shows that the first step involves selection of a base platform ortemplate from a database of chosen base platforms. The next step asshown in block 110 is to select the desired number of rooms for thatfloor or base platform. Next, as shown in block 120, calculations aremade to determine the possible room sizes that will work with theselected base platform. The database of limited and predetermined roomsizes imposes restrictions on the allowable sizes. The limitations mayrequire the room sizes to be evenly divisible by two such that adimension of ten feet is allowed, but 11 is not. In addition, rules maybe imposed such as disallowing any room dimension less than three feet.

[0027] After the calculations have filtered out room sizes that will notwork, the results may be displayed to show the base platform andacceptable room sizes as shown in block 130.

[0028] The base platforms of fixed dimensions of the invention areintegrated with appropriate standardized foundation elements andappropriately sized systems of floor and roof trusses. Kitchens,bathrooms, stairways and dormer subassemblies can be sized for eachclass size of base platform as desired. In addition, the insulation,siding, roofing, plumbing, heating, cooling, ventilation, health andsafety, wiring and trim can all achieve cost savings due to the systemand methods of the invention.

[0029] The present invention utilizes a database that may be manipulatedby the user to design a house or other shelter, size and arrange itsrooms and decorate the rooms. A design module may be overlaid with a CADmodule that would permit graphic modification to any design in thedesign module. The database provides information to the design moduleabout the common features, standard data, previously input informationand constraints. The database is modified and supplemented by initialuser input, user created standards and part modifications.

[0030] The design module information may be output to a visual outputmodule that displays the design on a video display and/or printer. Adetailing module may perform calculations of useful information such aslabor costs and bills of material utilizing the information from thedesign module.

[0031] The database includes a system database that includes data commonto all jobs and a job database that includes data for the specificproject at hand. The system database includes the essential designinformation for sitework, foundation, framing, exterior walls, roofing,interior specialties, mechanical and electrical systems, residentialbuilding types, exterior wall construction, residential configurationsand residential garage types, data on square foot costs, assembly costsand location cost factors. The job database is initially empty and isprogressively filled with data selected from the system database. Thejob database includes information as to room sizes and configurations aswell as locations and sizes of fixed objects in the rooms.

[0032] The system then moves to a placement function, which may bedisplayed in a three dimensional mode, a wall placement mode or a planview placement mode. Each mode provides the indicated view correspondingto the arrangement of the floor platform or room.

[0033] During the placement function, the user selects the room layoutarrangements and the placement room layout arrangements and theplacement and dimensions of major locational restraints such asdoorways, windows and appliances. The visual output function displaysthe relevant information on a video display or to a printer as desired.In the three dimensional mode, icons are called form the job databaseand the system database provides a catalogue of available custom parts.The process of customized creation of particular features of rooms or ofhouses, from a vast array of possibilities in the database is an exampleof a user selected standard. The user can compile a personalized designof any combination of parts used in producing the home. The personalizeddesign is stored in the database and used in the detailing operation.

[0034] An override parts function may be provided in the event that thesystem did not include a modification proposed by a user. The usercreated standards function permits modification of previously definedstandards and the override parts function may permit new standards. Themodifications are introduced to the job database and thereafter themodification is included in all further design modifications, detailing,pricing and display.

[0035] The system may also include a listing of each part required forthe assembly of the home. The types of components are provided by thedesign module and the required parts are in the database. Thisinformation is used to compile a summary of all parts required.

[0036] This list includes a full parts listing of every required pieceof material and hardware to construct the residence. A materialsrequirement routine determines the number of standard pieces of materialthat must be purchase to provide the necessary material for the job. Thematerial requirement and the hardware requirements together provide abill of materials.

[0037] The system database also includes a list of standard purchaseprices for every material and item of hardware. The total cost ofmaterial and hardware is easily calculated after all components havebeen selected. Labor costs and total hours of labor for each assemblystep required to produce the home are determined from the design of thehome and the standards in the database. Standard hours of labor requiredto perform the various operations are determined from the experience ofprior builders and input of that data into the systems database. Thestandard hours of labor are used in conjunction with the data from thedesign module and materials lists to calculate the number of hours oflabor required and the total labor cost.

[0038] The sum of the material and labor costs is the total job cost.Profit is added to yield a total job estimate. At the completion of ajob, the actual labor and material usage can be compared with theprojected values to determine sources of error and permit refinement ofthe standard values used in future job cost analysis. These values inturn are entered into the database.

[0039] Each base platform can be used to make a great number of basedesigns, each of which in turn may be expressed as a different type orcollection. For example, a 24×28 base platform could easily be expressedas a “City Collection” of 10-15 base designs for urban and suburbanlocations; a “Country Collection” of 5-10 base designs in a more ruralsetting and an “Affordable Collection” of 10-15 base designs distilleddown into urban settings with simplified options and reduced detail.

[0040] Within each collection each base design will have adistinguishing architectural identity which develops from the coreplatform systems, such as the foundation, wall panels, floor trusses andMechanicals/Electricals/Plumbing (MIE/P). The architectural character issimply developed through exterior elevations and materials to establishthe desired identity. Interior cabinetry, millwork, finishes andfixtures provide diversity. Supplemental architectural elements providediversity such as porches, horizontal expansions (master suite, guestsuite), garages, storage out buildings or enclosures, fencing, mailboxes, fenestration and detail patterns within a given architecturalcharacter. Each base unit within a collection will have its own range ofdevelopments.

[0041] A drawing package for a particular house from a collection couldinclude the following:

[0042] *—site/house specific document

[0043] p—platform basis document

[0044] * Site Plan/Survey Site/soil documentation/testing

[0045] * Landscape plan and plant materials schedule

[0046] p—Landscape spec and installation guidelines

[0047] p—Lower Level Plan (Architectural/Reference Overview)

[0048] p—Level One Framing Plan—Component, assembly drawings

[0049] p—Mechanical Plan—Spec's, assembly drawings

[0050] p—Plumbing Plan—Spec's, assembly drawings

[0051] p—Electrical Plan—Spec's, assembly drawings

[0052] *—Finish Plans—Finish Sched. and specs, floor/wall/ceilings

[0053] p—Level One Plan (Architectural/Reference Overview)

[0054] p—Level One Framing Plan—Component, assembly drawings

[0055] p—Mechanical Plan—Spec's, assembly drawings

[0056] p—Plumbing Plan—Spec's, assembly drawings

[0057] p—Electrical Plan—Spec's, assembly drawings

[0058] *—Finish Plans—Finish Sched. and specs, floor/wall/ceilings

[0059] p—Level Two Plan—Same as Level One above

[0060] *Roof Plan

[0061] specs

[0062] roof truss components

[0063] assembly drawings

[0064] p—Sections—(Architectural/Reference Overview)

[0065] Longitudinal and Lateral—component, assembly drawings

[0066] *—Elevations—(Architectural/Reference Overview)

[0067] p—wall component and assembly drawings

[0068] *—window details—Sched/spec, assembly drawings

[0069] *—siding /trim details—Spec, assembly drawings

[0070] *—Millwork Package

[0071] *—Cabinetry Package

[0072]FIG. 2 shows the components of a drawing package as describedabove in a chart form.

[0073] The basis of the system is approaching homebuilding from theoutside in. That is, instead of looking at a home in the conventionalterms of how many rooms are desired and building the house from theinside out, the buyer would select a home based on which of the manyfixed platforms will be in their price range and be capable of carryingthe rooms, sizes and features they desire. By forcing the home buyers todrop custom features that they don't even appreciate, the builder isable to attain economies of scale by eliminating custom choices thatrequire expensive skilled craftsman and expensive materials. Once theplatform is selected, the buyer selects the number of rooms desired andplaces the non-load bearing walls. Since the mechanicals are all basedon the selected platform, they can be ordered up and delivered at leastpartially prefabricated which greatly lowers their cost and also makesthe installation possible by lower skilled (and paid) assemblers.

[0074] The unique operating system of fixed dimensional parts calibratedto fixed platforms is characterized as follows:

[0075] The platform horizontal space is an X, Y orthogonal area whosedimensions are determined by the size choice of X and Y.

[0076] Any desired dimensions of X and Y may be selected to providespace for particular uses.

[0077] Once fixed, the X and Y dimensions indicate satisfactoryorthogonal dimensions, which are likewise fixed by the spacerequirements of specific needs.

[0078] The orthogonal dimensions X, Y, Z define the wall area of a box,and indicate the appropriate dimensions for the box top.

[0079] The box top (roof) are is defined by the size of the X and Ycoordinates as modified by the pitch (slope or slopes) one selects.

[0080] Any desired number of boxes may be stacked or arranged laterally.

[0081] The size values of X, Y, Z and box top (roof) area serve primarydeterminants of materials costs through defining the areas involved andindicating the scope of the stresses to be resisted. Basement type, andextent also enter the cost picture specified by the other dimensions andthe soil conditions on site.

[0082] In practical terms “small”, “medium”, and “large” defineappropriate box/roof sizes to meet the budgets available forconstruction.

[0083] Once the size of the box/roof is fixed the dimensionality of allcomponent material parts is calibrated to this size.

[0084] Once material dimensionality is fixed and space dimensionality isestablished, parts become interchangeable between members of each sizeclass of boxes. Collections of houses/shelters may require manythousands of parts.

[0085] In these fixed circumstances and composite components parts maybe manufactured in quantity anywhere and simply assembled on job site,allowing reduction in waste control of dimensional creep, qualitycontrol and increased safety to the assemblers as well as conservationin time for the entire assembly.

[0086] Once dimensionalities are fixed it is readily apparent thathouses/shelters can be regarded as interactive systems of systems whichcan be engineered as parts or as composites.

[0087] Every element in the house/shelter system is understood in termsof the whole—in terms of the desired operating system made possible bythe claimed technique.

[0088] Any variation in the whole has consequences for the integratedparts; any change in the elements affects the whole, thusstandardization is necessary to achieve the economies of scaleunobtainably by one of a kind construction.

[0089] The operating system of fixed dimensions calibrated to a fixedplatform may be designed and engineered to any desired level ofcomplexity using parts of any desired materials, and level of quality,character, or workmanship.

[0090] The replication of elements allows for standard classes ofstructures sharing known characteristics and costing established amountsthus defining replicable finance/insurance levels and allowing easydiffusion of latest technologies and health/safety methodologies.

[0091] The box/top structure may be clothed in any desired, estheticallysatisfactory kinds and styled types of materials, allowing masspersonalization of what would otherwise be fully mass producedstructures. Lack of personalization has been a drawback to most types of“manufactured” housing.

[0092] Use of pre-engineered truss systems in floors and roofseliminates the need for load-bearing interior walls, allowingpersonalized choice of space utilization; more than one interior spaceuse may be desired as successive generations of tenants occupy a givenhouse/structure during the century or so of its existence.

[0093] Use of the claimed construction methodology brings theefficiencies of scale to bear in the construction of hundreds ofthousands of houses/shelters produced every year. This bringsinnumerable advantages to individuals, municipalities and the nation,which have hitherto been chained to inflexible, out of date, wasteful,and more dangerous construction techniques to produce the nexus of ourcivilization—the house and similar structures.

[0094] While this invention may be embodied in many different forms,there are shown in the drawings and described in detail herein specificpreferred embodiments of the invention. The present disclosure is anexemplification of the principles of the invention and is not intendedto limit the invention to the particular embodiments illustrated. Use ofthe terms homes, houses and housing herein is intended to include alltypes of shelters.

[0095] This completes the description of the preferred and alternateembodiments of the invention. Those skilled in the art may recognizeother equivalents to the specific embodiment described herein whichequivalents are intended to be encompassed by the claims attachedhereto.

What is claimed is:
 1. A construction system for building multiplepersonalized shelters and homes comprising: (a) a plurality of templatesconsisting of a predetermined plurality of base platforms of fixeddimensions; (b) a computer programmed to include the templates and allacceptable room numbers and sizes for each template; and (c) displaymeans for displaying a floor plan for each base platform for showingeach possible layout of rooms per base platform.
 2. A system forstandardizing the construction of housing comprising: (a) means forstoring a set of templates of a predetermined plurality of baseplatforms of fixed dimensions; (b) means for generating a set ofstandardized room sizes; (c) input means for selecting the desired baseplatform, room sizes and room number; (d) processor means fordetermining the number of rooms and sizes possible for the selected baseplatform; and (e) display means for displaying the rooms and sizes forthe base platform.
 3. A method for constructing multiple personalizedhomes comprising the steps of: (a) predeterming a plurality of baseplatforms of fixed dimensions to serve as templates; (b) selecting abase platform template; (c) selecting the number of rooms into which thebase platform template is to carry; (d) determining the size of eachroom desired with each dimension being evenly divisible by two; and (e)constructing said individual personalized home based on the sizes asdetermined.
 4. A method for constructing multiple personalized homescomprising the steps of: (a) predetermining a plurality of baseplatforms of fixed dimensions to serve as templates; (b) selecting abase platform template; (c) selecting the number of rooms into which thebase platform template is to carry; (d) calculating possible room sizesfor the base template and filtering out room sizes which result innon-standardized sizes; (e) selecting room sizes from the filtered list;and (e) constructing said home based on the sizes as determined.
 5. Asystem for building multiple personalized shelters utilizing baseplatforms of fixed dimensions which permits building withinterchangeable parts and sub-assemblies.
 6. A method for buildingmultiple personalized houses at a lower cost comprising the steps of:(a) selecting a building platform from a pre-defined set of homeplatforms; (b) preparing floors and ceilings using trusses to eliminatethe need for interior load bearing walls; (c) utilizing a standardizedset of dimensions to develop the floor plans of room walls, hallways,doors and windows; and (d) assembling the houses using interchangeableparts defined by the predefined set of home platforms and standardizedset of dimensions.
 7. A method for lowering home building costscomprising the steps of: (a) setting up an organizing group that definesand sets protocols and standards of fixed dimensions for standardizedplatforms for the housing industry; (b) utilizing said protocols andstandards to produce standards for interchangeable parts that will beused on such standardized platforms; (c) preparing a homebuilding planbased on the standardized platforms and interchangeable parts; (d)bringing the interchangeable parts to the building site; (e) bringingassemblers to the building site to assemble the home based on thestandardized platform; and (f) assembling the home.
 8. A home buildingprocess to simplify and reduce costs of construction comprising thesteps of: (a) setting up a system of fixed platforms; (b) utilizingtruss systems to avoid load bearing interior walls; (c) developinginterchangeable standardized components based on said fixed platforms;and (d) utilizing assemblers at the home site to assemble theinterchangeable standardized components to said fixed platforms.
 9. Ahome building process to simplify and reduce costs of constructioncomprising the steps of: (a) establishing a system of fixed platformsfrom which builders and home buyers select their home foundation; (b)utilizing truss systems to avoid load-bearing interior walls; (c)standardizing components for the fixed platforms to produceinterchangeable parts needing less customization for installation; (d)utilizing assemblers to install said standardized components instead ofskilled tradesmen; and (e) assembling the house using the fixedplatforms selected and interchangeable components with assemblers.